Merritt Tool Co., an aerospace job shop in East Texas, is finding success in a strategy that originated in Japan. Called "5S," the approach was part of the renowned Toyota production system, which is recognized for its efficiency and elimination of waste. While the five words that comprise 5S vary slightly depending on the interpretation of the original Japanese words, 5S stands for sort, simplify, shine, standardize and sustain for Merritt Tool of Kilgore, Texas.

By following these five steps, the job shop has realized tremendous benefits, including reduced costs, quicker setup time and improved quality. All these gains provide a huge competitive advantage for the 65-person job shop, where the majority of machine tools are multi-axis CNC types appropriate for aerospace workpieces in aluminum and titanium. In fact, the effects of 5S on the shop are immediately apparent even to the casual observer. For one thing, the shop is amazingly free of clutter. And workstations are so carefully organized that visitors can discern what the next step is in the process and what it entails. Moreover, 5S has sped the company's transition into lean manufacturing.

Implementing 5S entailed the unwavering commitment of senior management, from general manager Larry Simmons to president A.P. Merritt, Jr. "The main thing is to understand the concepts and principles of 5S, then devote time and resources to applying them," Simmons, who headed the implementation of the strategy, tells Modern Machine Shop. "A half-hearted commitment to 5S is doomed to fail." And perhaps most importantly, the initiative must win the support of all workers. "5S has been successful here mainly because our employees wanted it to succeed. Their hard work and dedication have been the biggest factors in making this work," observes Simmons.

According to Simmons, the first S or "sort" entails separating necessary items from unnecessary ones. While needed objects are organized, unneeded ones are thrown out. To "simplify," the job shop arranges items carefully, affixing labels to identify things and to list information about size, specifications, maintenance, etc. For example, items that are used daily are left at their point of use, while tools and items that are employed on a regular basis are placed on shadowboards, where they are prominently displayed, easy to reach, neatly arranged and ergonomically organized, with heavier pieces placed lower. An empty spot on a shadowboard provides a clear visual indication to operators that a tool is missing. Meanwhile, items that are used about once a week are kept in cabinets in the work area. These cabinets, like the shadowboards, are highly accessible, with front panels made of clear acrylic plastic. "See-through doors mean there's no place to hide junk, and nobody has to guess what's inside," notes Simmons. What's more, cabinets and their contents are meticulously labeled.

To "shine," Merritt Tool stripped and repainted floors with a gleaming, wear-resistant coating. The light color not only livened up the space but also made stray chips and dirt more conspicuous. Moreover, shop workers scrupulously cleaned machine tools and work areas, repainted some machines and touched up others to mask scratches and wear. Simmons also reworked some machine enclosures to better contain chips or coolant splashes and reconfigured several hydraulic lines at the back of machines so they wouldn't attract dirt and chips. This emphasis on cleanliness made the environment safer and more comfortable, encouraging employees to work more meticulously and imparting a favorable impression on visitors and customers. Moreover, it simplified maintenance.

The last 2 S's—"standardize" and "sustain"—are also extremely important parts of the equation. By developing and adhering to standards, the shop is able to be consistent in following the first three S's. Standardizing entails recording procedures for maintaining the work area. The shop not only employs checklists but also uses digital photos showing ideal conditions to remind workers how to keep things organized. And the final S is perhaps the most crucial of them all, underlining the importance of self-discipline and commitment. "It's more than just maintaining new habits and not backsliding into old ones," says Simmons. Sustaining involves a continuing effort to get better at sorting, simplifying, shining, standardizing—and even at sustaining itself.

With its emphasis on visibility and accessibility, 5S has certainly made a huge difference for Merritt Tool. It has propelled the company toward lean manufacturing as well as cellular manufacturing. What's more, it has delivered tangible benefits, from dramatically reduced setup and changeover time to improved work quality.

Source:

This Shop Really Shines…And Sorts, Simplifies, Standardizes and Sustains
Mark Albert
Modern Machine Shop, December 23, 2003
www.mmsonline.com/articles/010401.html